Classifications

• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C233/00—Carboxylic acid amides
  • C07C233/01—Carboxylic acid amides having carbon atoms of carboxamide groups bound to hydrogen atoms or to acyclic carbon atoms
  • C07C233/12—Carboxylic acid amides having carbon atoms of carboxamide groups bound to hydrogen atoms or to acyclic carbon atoms having the nitrogen atom of at least one of the carboxamide groups bound to a carbon atom of a hydrocarbon radical substituted by halogen atoms or by nitro or nitroso groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/04—Monomers containing three or four carbon atoms
  • C08F110/06—Propene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/65—Pretreating the metal or compound covered by group C08F4/64 before the final contacting with the metal or compound covered by group C08F4/44
  • C08F4/652—Pretreating with metals or metal-containing compounds
  • C08F4/654—Pretreating with metals or metal-containing compounds with magnesium or compounds thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • B01J31/02—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C233/00—Carboxylic acid amides
  • C07C233/01—Carboxylic acid amides having carbon atoms of carboxamide groups bound to hydrogen atoms or to acyclic carbon atoms
  • C07C233/02—Carboxylic acid amides having carbon atoms of carboxamide groups bound to hydrogen atoms or to acyclic carbon atoms having nitrogen atoms of carboxamide groups bound to hydrogen atoms or to carbon atoms of unsubstituted hydrocarbon radicals
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C233/00—Carboxylic acid amides
  • C07C233/64—Carboxylic acid amides having carbon atoms of carboxamide groups bound to carbon atoms of six-membered aromatic rings
  • C07C233/67—Carboxylic acid amides having carbon atoms of carboxamide groups bound to carbon atoms of six-membered aromatic rings having the nitrogen atom of at least one of the carboxamide groups bound to a carbon atom of a hydrocarbon radical substituted by singly-bound oxygen atoms
  • C07C233/68—Carboxylic acid amides having carbon atoms of carboxamide groups bound to carbon atoms of six-membered aromatic rings having the nitrogen atom of at least one of the carboxamide groups bound to a carbon atom of a hydrocarbon radical substituted by singly-bound oxygen atoms with the substituted hydrocarbon radical bound to the nitrogen atom of the carboxamide group by an acyclic carbon atom
  • C07C233/69—Carboxylic acid amides having carbon atoms of carboxamide groups bound to carbon atoms of six-membered aromatic rings having the nitrogen atom of at least one of the carboxamide groups bound to a carbon atom of a hydrocarbon radical substituted by singly-bound oxygen atoms with the substituted hydrocarbon radical bound to the nitrogen atom of the carboxamide group by an acyclic carbon atom of an acyclic saturated carbon skeleton
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F10/04—Monomers containing three or four carbon atoms
  • C08F10/06—Propene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
  • B01J27/24—Nitrogen compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2410/00—Features related to the catalyst preparation, the catalyst use or to the deactivation of the catalyst
  • C08F2410/06—Catalyst characterized by its size
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/65—Pretreating the metal or compound covered by group C08F4/64 before the final contacting with the metal or compound covered by group C08F4/44
  • C08F4/652—Pretreating with metals or metal-containing compounds
  • C08F4/654—Pretreating with metals or metal-containing compounds with magnesium or compounds thereof
  • C08F4/6543—Pretreating with metals or metal-containing compounds with magnesium or compounds thereof halides of magnesium
  • C08F4/6545—Pretreating with metals or metal-containing compounds with magnesium or compounds thereof halides of magnesium and metals of C08F4/64 or compounds thereof

Definitions

• the present disclosure relates to procatalyst compositions containing a substituted amide ester, the incorporation of the same in catalyst compositions and the process of making olefin-based polymer using said catalyst compositions and the resultant olefin-based polymers produced therefrom.
• Olefin-based polymers with broad molecular weight distribution find increasing applications in thermoforming; pipe-, foam-, blow-molding; and films.
• Ziegler-Natta catalyst compositions for the production of olefin-based polymers, particularly propylene-based polymers, with broad MWD are known.
• Ziegler-Natta catalyst compositions typically include a procatalyst composed of a transition metal halide (i.e., titanium, chromium, vanadium) supported on a metal or metalloid compound, such as magnesium chloride or silica, the procatalyst complexed with a cocatalyst such as an organoaluminum compound.
• a transition metal halide i.e., titanium, chromium, vanadium
• a metal or metalloid compound such as magnesium chloride or silica
• a cocatalyst such as an organoaluminum compound.
• olefin-based polymers Given the perennial emergence of new applications for olefin-based polymers, the art recognizes the need for olefin-based polymers with improved and varied properties. Desirable would be a Ziegler-Natta catalyst composition that produces olefin-based polymer, and propylene-based polymer in particular, with broad molecular weight distribution (MWD) with less process constraints and less equipment.
• MWD molecular weight distribution
• the present disclosure is directed to procatalyst compositions containing substituted amide ester as an internal electron donor and the application of the same in catalyst compositions and polymerization processes.
• Catalyst compositions containing the substituted amide ester find application in olefin polymerization processes.
• the present substituted amide ester-containing catalyst compositions have high catalyst activity and/or high selectivity and produce propylene-based olefins with high isotacticity and broad molecular weight distribution.
• a procatalyst composition in an embodiment, includes a combination of a magnesium moiety, a titanium moiety and an internal electron donor.
• the internal electron donor includes a substituted amide ester.
• the substituted amide ester has the structure (II) below.
• R 1 -R 6 are the same or different. Each of R 1 -R 6 is selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms. At least one of R 1 -R 6 is a hydrocarbyl group having at least two carbon atoms. Alternatively, each of R 3 and R 5 is a hydrocarbyl group having 1-20 carbon atoms. R 11 -R 13 and R 21 -R 23 are the same or different. Each of R 11 -R 13 and R 21 -R 23 is selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms.
• the procatalyst composition includes a combination of a magnesium moiety, a titanium moiety and an internal electron donor.
• the internal electron donor includes a substituted amide ester.
• the substituted amide ester has the structure (II) below.
• R 1 -R 6 , R 11 -R 13 , and R 21 -R 23 are the same or different.
• Each of R 1 -R 6 , R 11 -R 13 , and R 21 -R 23 is selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms.
• At least one of R 1 -R 6 is a hydrocarbyl group having 1-20 carbon atoms.
• At least one of R 11 -R 13 , R 21 -R 23 is a hydrocarbyl group having 1-20 carbon atoms.
• a catalyst composition in an embodiment, includes a procatalyst composition.
• the procatalyst composition includes a substituted amide ester of structure (II).
• the procatalyst composition also includes a cocatalyst.
• a process for producing an olefin-based polymer includes contacting, under polymerization conditions, an olefin with a catalyst composition comprising a substituted amide ester, and forming an olefin-based polymer.
• An advantage of the present disclosure is the provision of an improved procatalyst composition.
• An advantage of the present disclosure is the provision of an improved catalyst composition for the polymerization of olefin-based polymers.
• An advantage of the present disclosure is the provision of a phthalate-free catalyst composition and a phthalate-free olefin-based polymer produced therefrom.
• An advantage of the present disclosure is a catalyst composition that produces a propylene-based polymer with broad molecular weight distribution and/or high isotacticity.
• An advantage of the present disclosure is a catalyst composition that produces a propylene-based polymer with broad molecular weight distribution in a single reactor.
• a procatalyst composition in an embodiment, includes a combination of a magnesium moiety, a titanium moiety and an internal electron donor.
• the internal electron donor includes a substituted amide ester.
• the procatalyst composition is a reaction product of a procatalyst precursor, a substituted amide ester, an optional halogenating agent, and an optional titanating agent.
• the procatalyst composition is produced by halogenating/titanating a procatalyst precursor in the presence of the internal electron donor.
• an “internal electron donor” is a compound added or otherwise formed during formation of the procatalyst composition that donates at least one pair of electrons to one or more metals present in the resultant procatalyst composition.
• the internal electron donor includes the substituted amide ester.
• the internal electron donor (1) regulates the formation of active sites, (2) regulates the position of titanium on the magnesium-based support and thereby enhances catalyst stereoselectivity, (3) facilitates conversion of the magnesium and titanium moieties into respective halides and (4) regulates the crystallite size of the magnesium halide support during conversion.
• the internal electron donor yields a procatalyst composition with enhanced stereoselectivity.
• the procatalyst precursor may be a magnesium moiety compound (MagMo), a magnesium mixed metal compound (MagMix), or a benzoate-containing magnesium chloride compound (BenMag).
• the procatalyst precursor is a magnesium moiety (“MagMo”) precursor.
• the “MagMo precursor” contains magnesium as the sole metal component.
• the MagMo precursor includes a magnesium moiety.
• suitable magnesium moieties include anhydrous magnesium chloride and/or its alcohol adduct, magnesium alkoxide or aryloxide, mixed magnesium alkoxy halide, and/or carbonated magnesium dialkoxide or aryloxide.
• the MagMo precursor is a magnesium di-(C 1-4 )alkoxide.
• the MagMo precursor is diethoxymagnesium.
• the MagMix includes magnesium and at least one other metal atom.
• the other metal atom can be a main group metal or a transition metal, or a transition metal of IIIB-VIIIB element.
• the transition metal is selected from Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Y, Zr, Nb, and Hf.
• the MagMix precursor is a mixed magnesium/titanium compound (“MagTi”).
• the “MagTi precursor” has the formula Mg d Ti(OR e ) f X g wherein R e is an aliphatic or aromatic hydrocarbon radical having 1 to 14 carbon atoms or COR′ wherein R′ is an aliphatic or aromatic hydrocarbon radical having 1 to 14 carbon atoms; each OR e group is the same or different; X is independently chlorine, bromine or iodine, preferably chlorine; d is 0.5 to 56, or 2 to 4; f is 2 to 116 or 5 to 15; and g is 0.5 to 116, or 1 to 3.
• the procatalyst precursor is a benzoate-containing magnesium chloride material.
• a “benzoate-containing magnesium chloride” (“BenMag”) is a magnesium chloride procatalyst (i.e., a halogenated procatalyst precursor) containing a benzoate internal electron donor.
• the BenMag material may also include a titanium moiety, such as a titanium halide.
• the benzoate internal donor is labile and can be replaced by other electron donors during procatalyst synthesis.
• Nonlimiting examples of suitable benzoate groups include ethyl benzoate, methyl benzoate, ethyl p-methoxybenzoate, methyl p-ethoxybenzoate, ethyl p-ethoxybenzoate, ethyl p-chlorobenzoate.
• the benzoate group is ethyl benzoate.
• suitable BenMag procatalyst precursors include catalysts of the trade names SHACTM 103 and SHACTM 310 available from The Dow Chemical Company, Midland, Mich.
• the BenMag procatalyst precursor is a product of halogenation of any procatalyst precursor (i.e., a MagMo precursor or a MagMix precursor) in the presence of a benzoate compound with the structure (I)
• R 1 -R 5 are H, a C 1 -C 20 hydrocarbyl group which may contain heteroatoms including F, Cl, Br, I, O, S, N, P, and Si
• R′ is a C 1 -C 20 hydrocarbyl group which may optionally contain heteroatom(s) including F, Cl, Br, I, O, S, N, P, and Si.
• R 1 -R 5 are selected from H and a C 1 -C 20 alkyl group and R′ is selected from a C 1 -C 20 alkyl group and an alkoxyalkyl group.
• Halogenation/titanation of the procatalyst precursor in the presence of the internal electron donor produces a procatalyst composition which includes a combination of a magnesium moiety, a titanium moiety, and the internal electron donor (a substituted amide ester).
• the magnesium and titanium moieties are respective halides, such as magnesium chloride and titanium chloride. Bounded by no particular theory, it is believed that the magnesium halide is a support upon which the titanium halide is deposited and into which the internal electron donor is incorporated.
• the resulting procatalyst composition has a titanium content of from about 1.0 percent by weight to about 6.0 percent by weight, based on the total solids weight, or from about 1.5 percent by weight to about 5.5 percent by weight, or from about 2.0 percent by weight to about 5.0 percent by weight.
• the weight ratio of titanium to magnesium in the solid procatalyst composition is suitably between about 1:3 and about 1:160, or between about 1:4 and about 1:50, or between about 1:6 and 1:30.
• the internal electron donor is present in an amount from about 0.1 wt % to about 20.0 wt %, or from about 1.0 wt % to about 15 wt %.
• the internal electron donor may be present in the procatalyst composition in a molar ratio of internal electron donor to magnesium of from about 0.005:1 to about 1:1, or from about 0.01:1 to about 0.4:1. Weight percent is based on the total weight of the procatalyst composition.
• Ethoxide content in the procatalyst composition indicates the completeness of conversion of precursor metal ethoxide into a metal halide.
• the substituted amide ester assists in converting ethoxide into halide during halogenation.
• the procatalyst composition includes from about 0.01 wt % to about 1.0 wt %, or from about 0.05 wt % to about 0.5 wt % ethoxide. Weight percent is based on the total weight of the procatalyst composition.
• the internal electron donor is a mixed internal electron donor.
• a “mixed internal electron donor” is (i) a substituted amide ester, (ii) an electron donor component that donates a pair of electrons to one or more metals present in the resultant procatalyst composition, and (iii) optionally other components.
• the electron donor component is a benzoate, such as ethyl benzoate and/or methoxypropan-2-yl benzoate.
• the procatalyst composition with the mixed internal electron donor can be produced by way of the procatalyst production procedure as previously disclosed.
• the benzoate is introduced from the addition of the benzoate during the procatalyst production.
• the benzoate is from the BenMag procatalyst precursor.
• the benzoate is from decomposition of a portion of the substituted amide ester electron donor.
• the internal electron donor includes the substituted amide ester and optionally an electron donor component.
• the substituted amide ester has the structure (II) below:
• R 1 -R 6 are the same or different.
• Each of R 1 -R 6 is selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms. At least one of R 1 -R 6 is a hydrocarbyl group having at least 2 carbon atoms. Alternatively, each of R 3 and R 5 is a hydrocarbyl group having 1-20 carbon atoms.
• Each of R 11 -R 13 and R 21 -R 23 are the same or different and selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms.
• hydrocarbyl or “hydrocarbon” is a substituent containing only hydrogen and carbon atoms, including branched or unbranched, saturated or unsaturated, cyclic, polycyclic, fused, or acyclic species, and combinations thereof.
• hydrocarbyl groups include alkyl-, cycloalkyl-, alkenyl-, alkadienyl-, cycloalkenyl-, cycloalkadienyl-, aryl-, aralkyl, alkylaryl, and alkynyl-groups.
• substituted hydrocarbyl or “substituted hydrocarbon” is a hydrocarbyl group that is substituted with one or more nonhydrocarbyl substituent groups.
• a nonlimiting example of a nonhydrocarbyl substituent group is a heteroatom.
• a “heteroatom” is an atom other than carbon or hydrogen.
• the heteroatom can be a non-carbon atom from Groups IV, V, VI, and VII of the Periodic Table.
• Nonlimiting examples of heteroatoms include: halogens (F Cl, Br, I), N, O, P, B, S, and Si.
• a substituted hydrocarbyl group also includes a halohydrocarbyl group and a silicon-containing hydrocarbyl group.
• halohydrocarbyl is a hydrocarbyl group that is substituted with one or more halogen atoms.
• sicon-containing hydrocarbyl group is a hydrocarbyl group that is substituted with one or more silicon atoms. The silicon atom(s) may or may not be in the carbon chain.
• At least two, or at least three, or at least 4, of R 1 -R 6 are a hydrocarbyl group having at least 2 carbon atoms.
• each of R 1 and R 2 is a hydrocarbyl group with at least two, or at least three, or at least four, or at least five, or at least six, carbon atoms.
• each of R 1 and R 2 is selected from an isopropyl group, an isobutyl group, a sec-butyl group, a cyclopentyl group, a cyclohexyl group, and combinations thereof.
• At least one of R 1 and R 2 is an isopropyl group. In a further embodiment, each of R 1 and R 2 is an isopropyl group.
• At least one of R 1 and R 2 is an isobutyl group. In a further embodiment, each of R 1 and R 2 is an iso-butyl group.
• At least one of R 1 and R 2 is a cyclopentyl group. In a further embodiment, each of R 1 and R 2 is a cyclopentyl group.
• each of R 1 and R 2 is a cyclohexyl group. In a further embodiment, each of R 1 and R 2 is a cyclohexyl group.
• At least one of R 11 -R 13 and at least one of R 21 -R 23 is a hydrocarbyl group having 1-20 carbon atoms.
• each of R 12 and R 22 is a hydrocarbyl group having at least 2 carbon atoms.
• the substituted amide ester has the structure (II) below:
• R 1 -R 6 are the same or different.
• Each of R 1 , R 2 , R 4 , and R 6 is selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms.
• Each of R 3 and R 5 is selected from a hydrocarbyl group having 1-20 carbon atoms.
• Each of R 11 -R 13 and R 21 -R 23 are the same or different and selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms.
• each of R 1 , R 2 , R 4 , and R 6 is hydrogen.
• Each of R 3 and R 5 is selected from a hydrocarbyl group having 1-6 carbon atoms. In a further embodiment, each of R 3 and R 5 is a methyl group.
• a procatalyst composition includes a combination of a magnesium moiety, a titanium moiety and an internal electron donor.
• the internal electron donor includes a substituted amide ester of the structure (II):
• R 1 -R 6 , R 11 -R 13 , and R 21 -R 23 are the same or different.
• Each of R 1 -R 6 , R 11 -R 13 , and R 21 -R 23 is selected from hydrogen and a hydrocarbyl group having 1-20 carbon atoms.
• At least one of R 1 -R 6 is a hydrocarbyl group having 1-20 carbon atoms.
• at least one of R 11 -R 13 and/or at least one of R 21 -R 23 is a hydrocarbyl group having 1-20 carbon atoms.
• each of R 1 , R 2 , R 12 , and R 22 is a methyl group.
• each of R 1 and R 2 is a methyl group and each of R 12 and R 22 is an ethyl group.
• each of R 1 and R 2 is a methyl group and each of R 12 and R 22 is a butyl group.
• each of R 1 and R 2 is a methyl group and each of R 12 and R 22 is a phenyl group.
• At least one of R 1 and R 2 is selected from an isopropyl group, an isobutyl group, a sec-butyl group, a cyclopentyl group, and a cyclohexyl group.
• At least one of R 12 and R 22 is a hydrocarbyl group having 1-6 carbon atoms.
• each of R 1 and R 2 is an isopropyl group, and each of R 12 and R 22 is a methyl group.
• each of R 1 and R 2 is an isopropyl group, and each of R 12 and R 22 is an ethyl group.
• each of R 1 and R 2 is an isobutyl group, and each of R 12 and R 22 is a methyl group.
• each of R 1 and R 2 is an isobutyl group, and each of R 12 and R 22 is an ethyl group.
• each of R 1 and R 2 is a cyclopentyl group, and each of R 12 and R 22 is a methyl group.
• each of R 1 and R 2 is a cyclopentyl group, and each of R 12 and R 22 is an ethyl group.
• each of R 1 and R 2 is a cyclohexyl group, and each of R 12 and R 22 is a methyl group.
• each of R 1 and R 2 is a cyclohexyl group, and each of R 12 and R 22 is an ethyl group.
• each of R 3 and R 5 is a methyl group
• each of R 12 and R 22 is a methyl group
• each of R 3 and R 5 is a methyl group
• each of R 12 and R 22 is an ethyl group.
• the internal electron donor and/or the mixed internal electron donor are/is phthalate-free.
• the procatalyst composition is phthalate-free.
• the present procatalyst composition may comprise two or more embodiments disclosed herein.
• a catalyst composition is provided.
• a catalyst composition is a composition that forms an olefin-based polymer when contacted with an olefin under polymerization conditions.
• the catalyst composition includes a procatalyst composition and a cocatalyst.
• the procatalyst composition can be any of the foregoing procatalyst compositions with an internal electron donor that is a substituted amide ester of structure (II) as disclosed herein.
• the catalyst composition may optionally include an external electron donor and/or an activity limiting agent.
• the internal electron donor of the catalyst composition is a mixed internal electron donor as disclosed above.
• the catalyst composition includes a cocatalyst.
• a “cocatalyst” is a substance capable of converting the procatalyst to an active polymerization catalyst.
• the cocatalyst may include hydrides, alkyls, or aryls of aluminum, lithium, zinc, tin, cadmium, beryllium, magnesium, and combinations thereof.
• suitable cocatalyst include trimethylaluminum, triethylaluminum, triisobutylaluminum, and tri-n-hexylaluminum.
• the cocatalyst is triethylaluminum.
• the molar ratio of aluminum to titanium is from about 5:1 to about 500:1, or from about 10:1 to about 200:1, or from about 15:1 to about 150:1, or from about 20:1 to about 100:1, or from about 30:1 to about 60:1. In another embodiment, the molar ratio of aluminum to titanium is about 35:1.
• the present catalyst composition includes an external electron donor.
• an “external electron donor” (or “EED”) is a compound added independent of procatalyst formation and includes at least one functional group that is capable of donating a pair of electrons to a metal atom.
• a “mixed external electron donor” (or “MEED”) is a mixture of two or more external electron donors. Bounded by no particular theory, it is believed that provision of one or more external electron donors in the catalyst composition effects the following properties of the formant polymer: level of tacticity (i.e., xylene soluble material), molecular weight (i.e., melt flow), molecular weight distribution (MWD), melting point, and/or oligomer level.
• the external electron donor may be selected from one or more of the following: a silicon compound, a bidentate compound, an amine, an ether, a carboxylate, a ketone, an amide, a carbamate, a phosphine, a phosphate, a phosphite, a sulfonate, a sulfone, a sulfoxide, and any combination of the foregoing.
• the EED is a silicon compound having the general formula (III): SiR m (OR′) 4-m (III) wherein R independently each occurrence is hydrogen or a hydrocarbyl or an amino group, optionally substituted with one or more substituents containing one or more Group 14, 15, 16, or 17 heteroatoms. R contains up to 20 atoms not counting hydrogen and halogen.
• R′ is a C 1-20 alkyl group, and m is 0, 1, or 2.
• R is C 6-12 aryl, alkylaryl or aralkyl, C 3-12 cycloalkyl, C 1-20 linear alkyl or alkenyl, C 3-12 branched alkyl, or C 2-12 cyclic amino group, R′ is C 1-4 alkyl, and m is 1 or 2.
• Nonlimiting examples of suitable silicon compounds for the EED include dialkoxysilanes, trialkoxysilanes, and tetraalkoxysilanes such as dicyclopentyldimethoxysilane (DCPDMS), diisopropyldimethoxysilane, bis(perhydroisoquinolino)dimethoxysilane methylcyclohexyldimethoxysilane, tetraethoxysilane, n-propyltrimethoxysilane, n-propyltriethoxysilane, diethylaminotriethoxysilane, bis(trimethylsilylmethyl)dimethoxysilane, and any combination thereof.
• DCPDMS dicyclopentyldimethoxysilane
• DCPDMS diisopropyldimethoxysilane
• the EED is a bidentate compound.
• a “bidentate compound” is a molecule or compound that contains at least two oxygen-containing functional groups separated by a C 2 -C 10 hydrocarbon chain, the oxygen-containing functional groups being the same or different and at least one oxygen-containing functional group being an ether group or a carboxylate group, the bidentate composition excluding phthalates.
• suitable oxygen-containing functional groups for the bidentate composition include carboxylate, carbonate, ketone, ether, carbamate, amide, sulfoxide, sulfone, sulfonate, phosphite, phosphinate, phosphate, phosphonate, and phosphine oxide.
• One or more carbon atoms in the C 2 -C 10 chain may be substituted with heteroatoms from Group 14, 15, and 16.
• One or more H atoms in the C 2 -C 10 chain may be substituted with alkyl, cycloalkyl, alkenyl, cycloalkenyl, aryl, alkylaryl, aralkyl, halogen, or functional groups containing a heteroatom from Group 14, 15, or 16.
• suitable bidentate compounds include diethers, succinates, dialkoxybenzenes, alkoxy ester, and/or diol esters.
• the bidentate compound is a diether such as 3,3-bis(methoxymethyl)-2,5-dimethylhexane, 4,4-bis(methoxymethyl)-2,6-dimethylheptane, and 9,9-bis(methoxymethyl)fluorene.
• the bidentate compound is a diol ester such as 2,4-pentanediol di(benzoate), 2,4-pentanediol di(2-methylbenzoate), 2,4-pentanediol di(4-n-butylbenzoate), 2,2,4-trimethyl-1,3-pentanediol diisobutyrate and/or 2,2,4-trimethyl-1,3-pentanediol dibenzoate.
• diol ester such as 2,4-pentanediol di(benzoate), 2,4-pentanediol di(2-methylbenzoate), 2,4-pentanediol di(4-n-butylbenzoate), 2,2,4-trimethyl-1,3-pentanediol diisobutyrate and/or 2,2,4-trimethyl-1,3-pentanediol dibenzoate.
• the carboxylate is a benzoate such as ethyl benzoate and ethyl 4-ethoxybenzoate.
• the external electron donor is a phosphite such as trimethyl phosphate, triethyl phosphate, and/or tri-n-propyl phosphite.
• the external electron donor is an alkoxy ester such as methyl 1-methoxybicylco[2.2.1]-hept-5-ene-2-carboxylate, methyl 3-methoxypropionate, methyl 3-methoxy-2-methylpropanoate, and/or ethyl 3-methoxy-2-methylpropanoate.
• the external electron donor is a succinate such as diethyl 2,3-diisopropyl succinate, di-n-butyl 2,3-diisopropylsuccinate, and/or diethyl 2,3-diisobutylsuccinate.
• the external electron donor is a dialkoxybenzene such as 1,2-diethoxybenzene, 1,2-di-n-butoxybenzene, and/or 1-ethoxy-2-n-pentoxybenzene.
• the external electron donor is an amine such as 2,2,6,6-tetramethylpiperidine.
• the EED may be a MEED which may comprise two or more of any of the foregoing EED compounds.
• the catalyst composition includes an activity limiting agent (ALA).
• an “activity limiting agent” (“ALA”) is a material that reduces catalyst activity at elevated temperature (i.e., temperature greater than about 85° C.).
• An ALA inhibits or otherwise prevents polymerization reactor upset and ensures continuity of the polymerization process.
• the activity of Ziegler-Natta catalysts increases as the reactor temperature rises.
• Ziegler-Natta catalysts also typically maintain high activity near the softening point temperature of the polymer produced.
• the heat generated by the exothermic polymerization reaction may cause polymer particles to form agglomerates and may ultimately lead to disruption of continuity for the polymer production process.
• the ALA reduces catalyst activity at elevated temperature, thereby preventing reactor upset, reducing (or preventing) particle agglomeration, and ensuring continuity of the polymerization process.
• the ALA may or may not be a component of the EED and/or the MEED.
• the activity limiting agent may be a carboxylic acid ester, a diether, a poly(alkene glycol), a succinate, a diol ester, and combinations thereof.
• the carboxylic acid ester can be an aliphatic or aromatic, mono- or poly-carboxylic acid ester.
• suitable carboxylic acid esters include benzoates, C 1-40 alkyl esters of aliphatic C 2-40 mono-/di-carboxylic acids, C 2-40 mono-/poly-carboxylate derivatives of C 2-100 (poly)glycols, C 2-100 (poly)glycol ethers, and any combination thereof.
• carboxylic acid esters include laurates, myristates, palmitates, stearates, oleates, and sebacates, and mixtures thereof.
• the ALA is ethyl 4-ethoxybenzoate or isopropyl myristate or di-n-butyl sebacate.
• the catalyst composition may include any of the foregoing external electron donors in combination with any of the foregoing activity limiting agents.
• the external electron donor and/or activity limiting agent can be added into the reactor separately.
• the external electron donor and the activity limiting agent can be mixed together in advance and then added to the catalyst composition and/or into the reactor as a mixture. In the mixture, more than one external electron donor or more than one activity limiting agent can be used.
• EED/ALA mixtures include dicyclopentyldimethoxysilane and isopropyl myristate; dicyclopentyldimethoxysilane and poly(ethylene glycol) laurate; diisopropyldimethoxysilane and isopropyl myristate; methylcyclohexyldimethoxysilane and isopropyl myristate; methylcyclohexyldimethoxysilane and ethyl 4-ethoxybenzoate; n-propyltrimethoxysilane and isopropyl myristate; dimethyldimethoxysilane and methylcyclohexyldimethoxysilane and isopropyl myristate; dicyclopentyldimethoxysilane and tetraethoxysilane and isopropyl myristate; dicyclopentyldimethoxysilane and tetraethoxysilane and
• the present catalyst composition may comprise two or more embodiments disclosed herein.
• a process for producing an olefin-based polymer includes contacting an olefin with a catalyst composition under polymerization conditions.
• the catalyst composition includes a substituted amide ester.
• the substituted amide ester can be any substituted amide ester of structure (II) as disclosed herein.
• the process further includes forming an olefin-based polymer.
• the catalyst composition includes a procatalyst composition and a cocatalyst.
• the procatalyst composition is any procatalyst composition disclosed herein and includes a substituted amide ester of structure (II) as the internal electron donor.
• the cocatalyst may be any cocatalyst as disclosed herein.
• the catalyst composition may optionally include an external electron donor and/or an activity limiting agent as previously disclosed.
• the olefin-based polymer contains substituted amide ester corresponding to the internal electron donor of structure (II) present in the procatalyst composition.
• the olefin-based polymer can be a propylene-based olefin, an ethylene-based olefin, and combinations thereof.
• the olefin-based polymer is a propylene-based polymer.
• One or more olefin monomers can be introduced into a polymerization reactor to react with the catalyst and to form a polymer, or a fluidized bed of polymer particles.
• suitable olefin monomers include ethylene, propylene, C 4-20 ⁇ -olefins, such as 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-decene, 1-dodecene and the like.
• polymerization conditions are temperature and pressure parameters within a polymerization reactor suitable for promoting polymerization between the catalyst composition and an olefin to form the desired polymer.
• the polymerization process may be a gas phase, a slurry, or a bulk polymerization process, operating in one, or more than one, polymerization reactor.
• the polymerization reactor may be a gas phase polymerization reactor, a liquid-phase polymerization reactor, or a combination thereof.
• hydrogen is a chain transfer agent and affects the molecular weight (and correspondingly the melt flow rate) of the resultant polymer.
• the polymerization process may include a pre-polymerization step and/or a pre-activation step.
• the process includes mixing the external electron donor (and optionally the activity limiting agent) with the procatalyst composition.
• the external electron donor and/or the activity limiting agent can be complexed with the cocatalyst and mixed with the procatalyst composition (pre-mix) prior to contact between the catalyst composition and the olefin.
• the external electron donor and/or the activity limiting agent can be added independently to the polymerization reactor.
• the olefin is propylene and optionally ethylene and/or 1-butene.
• the process includes forming a propylene-based polymer (propylene homopolymer or propylene copolymer) having one or more of the following properties:
• a process for producing an olefin-based polymer which includes contacting propylene with a catalyst composition comprising a substituted amide ester of structure (II) to form a propylene-based polymer.
• the contact between the propylene and the catalyst composition occurs in a first polymerization reactor under polymerization conditions.
• the process further includes contacting ethylene and optionally at least one other olefin in the presence of the propylene-based polymer.
• the contact between the ethylene, the olefin(s), and the propylene-based polymer occurs in a second polymerization reactor under polymerization conditions and forms a propylene impact copolymer.
• the first reactor and the second reactor operate in series whereby the effluent of the first reactor (i.e., the propylene-based polymer) is charged to the second reactor.
• Additional olefin monomer is added to the second polymerization reactor to continue polymerization.
• Additional catalyst composition (and/or any combination of individual catalyst components—i.e., procatalyst, cocatalyst, EED, ALA) may be added to the second polymerization reactor.
• the additional catalyst composition/components added to the second reactor may be the same or different than the catalyst composition/components introduced in the first reactor.
• the propylene-based polymer produced in the first reactor is a propylene homopolymer.
• the propylene homopolymer is charged to the second reactor where ethylene and propylene are contacted with each other in the presence of the propylene homopolymer.
• This forms a propylene impact copolymer having a propylene homopolymer continuous (or matrix) phase and a discontinuous phase (or rubber phase) selected from a propylene-based copolymer (i.e., a propylene/ethylene copolymer) or an ethylene-based copolymer (i.e., an ethylene/propylene copolymer).
• the discontinuous phase is dispersed in the continuous phase.
• the propylene impact copolymer may have an Fc value from about 1 wt % to about 50 wt %, or from about 10 wt % to about 40 wt %, or from about 20 wt % to about 30 wt %.
• Fc fraction copolymer
• the Fc value is based on the total weight of the propylene impact copolymer.
• the propylene impact copolymer may have an Ec value from about 1 wt % to about 100 wt %, or from about 20 wt % to about 90 wt %, or from about 30 wt % to about 80 wt %, or from about 40 wt % about 60 wt %.
• ethylene content (“Ec”) is the weight percent of ethylene present in the discontinuous phase of the propylene impact copolymer. The Ec value is based on the total weight of the discontinuous (or rubber) phase.
• the present processes for production olefin-based polymer may comprise two or more embodiments disclosed herein.
• any numerical range recited herein includes all values from the lower value to the upper value, in increments of one unit, provided that there is a separation of at least 2 units between any lower value and any higher value.
• amount of a component, or a value of a compositional or a physical property such as, for example, amount of a blend component, softening temperature, melt index, etc.
• amount of a blend component, softening temperature, melt index, etc. is between 1 and 100
• all individual values, such as, 1, 2, 3, etc., and all subranges, such as, 1 to 20, 55 to 70, 197 to 100, etc., are expressly enumerated in this specification.
• any numerical range recited herein includes any value or subrange within the stated range. Numerical ranges have been recited, as discussed herein, reference melt index, melt flow rate, and other properties.
• alkyl is a branched or unbranched, saturated or unsaturated acyclic hydrocarbon radical.
• suitable alkyl radicals include, for example, methyl, ethyl, n-propyl, i-propyl, n-butyl, t-butyl, i-butyl (or 2-methylpropyl), etc.
• the alkyls have 1 to 20 carbon atoms.
• aryl or “aryl group,” as used herein, is a substituent derived from an aromatic hydrocarbon compound.
• An aryl group has a total of from six to twenty ring atoms, and has one or more rings which are separate or fused, and may be substituted with alkyl and/or halo groups.
• the aromatic ring(s) may include phenyl, naphthyl, anthracenyl, and biphenyl, among others.
• blend or “polymer blend,” as used herein, is a blend of two or more polymers. Such a blend may or may not be miscible (not phase separated at molecular level). Such a blend may or may not be phase separated. Such a blend may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and other methods known in the art.
• composition includes a mixture of materials which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition.
• compositions claimed herein through use of the term “comprising” may include any additional additive, adjuvant, or compound whether polymeric or otherwise, unless stated to the contrary.
• the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability.
• the term “consisting of” excludes any component, step or procedure not specifically delineated or listed.
• ethylene-based polymer is a polymer that comprises a majority weight percent polymerized ethylene monomer (based on the total weight of polymerizable monomers), and optionally may comprise at least one polymerized comonomer.
• olefin-based polymer is a polymer containing, in polymerized form, a majority weight percent of an olefin, for example ethylene or propylene, based on the total weight of the polymer.
• olefin-based polymers include ethylene-based polymers and propylene-based polymers.
• polymer is a macromolecular compound prepared by polymerizing monomers of the same or different type. “Polymer” includes homopolymers, copolymers, terpolymers, interpolymers, and so on.
• interpolymer is a polymer prepared by the polymerization of at least two types of monomers or comonomers. It includes, but is not limited to, copolymers (which usually refers to polymers prepared from two different types of monomers or comonomers, terpolymers (which usually refers to polymers prepared from three different types of monomers or comonomers), tetrapolymers (which usually refers to polymers prepared from four different types of monomers or comonomers), and the like.
• propylene-based polymer is a polymer that comprises a majority weight percent polymerized propylene monomer (based on the total amount of polymerizable monomers), and optionally may comprise at least one polymerized comonomer.
• substituted alkyl is an alkyl as previously defined described in which one or more hydrogen atom bound to any carbon of the alkyl is replaced by another group such as a halogen, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, haloalkyl, hydroxy, amino, phosphido, alkoxy, amino, thio, nitro, silyl, and combinations thereof.
• Suitable substituted alkyls include, for example, benzyl, trifluoromethyl and the like.
• Melt flow rate is measured in accordance with ASTM D 1238-01 test method at 230° C. with a 2.16 kg weight for propylene-based polymers.
• Xylene Solubles is the weight percent of resin that stays in the solution after the resin is dissolved in hot xylene and the solution is allowed to cool to 25° C. (Gravimetric XS method according to ASTM D5492-06). XS is measured according to one of the two following procedures: (1) Viscotek method: 0.4 g of polymer is dissolved in 20 ml of xylenes with stirring at 130° C. for 30 minutes. The solution is then cooled to 25° C. and after 30 minutes the insoluble polymer fraction is filtered off. The resulting filtrate is analyzed by Flow Injection Polymer Analysis using a Viscotek ViscoGEL H-100-3078 column with THF mobile phase flowing at 1.0 ml/min.
• the column is coupled to a Viscotek Model 302 Triple Detector Array, with light scattering, viscometer and refractometer detectors operating at 45° C. Instrument calibration was maintained with Viscotek PolyCALTM polystyrene standards.
• NMR method XS is measured using a 1 H NMR method as described in U.S. Pat. No. 5,539,309, the entire content of which is incorporated herein by reference. Both of the methods are calibrated against the gravimetric ASTM method.
• Polydispersity Index is measured by an AR-G2 rheometer which is a stress control dynamic spectrometer manufactured by TA Instruments using a method according to Zeichner GR, Patel PD (1981) “A comprehensive Study of Polypropylene Melt Rheology”, Proc. of the 2 nd World Congress of Chemical Eng., Montreal, Canada.
• An ETC oven is used to control the temperature at 180° C. ⁇ 0.1° C. Nitrogen is used to purge the inside the oven to keep the sample from degradation by oxygen and moisture.
• a pair of 25 mm in diameter cone and plate sample holder is used. Samples are compress molded into 50 mm ⁇ 100 mm ⁇ 2 mm plaque. Samples are then cut into 19 mm square and loaded on the center of the bottom plate.
• the geometries of upper cone is (1) Cone angle: 5:42:20 (deg:min:sec); (2) Diameter: 25 mm; (3) Truncation gap: 149 micron.
• the geometry of the bottom plate is 25 mm cylinder.
• T MF Final melting point
• a 500-ml round-bottom flask is fit with magnetic stirrer, and is charged with ethyl 2 cyanoacetate (11.3 g, 0.1 mol) and anhydrous DMF (120 ml).
• ethyl 2 cyanoacetate 11.3 g, 0.1 mol
• anhydrous DMF 120 ml
• DBU 1,8-diazabycyclo[5.4.0]undec-7-ene
• DMF 1,8-diazabycyclo[5.4.0]undec-7-ene
• the mixture is stirred for another hour.
• the flask is cooled in an ice-water bath, and a solution of the iodide (0.2 mol, 1.0 equiv.) in DMF (40 ml) is added dropwise.
• the mixture is raised to room temperature and stirred for another 14 hours until all starting material is converted into the product (monitored by GC).
• the mixture is poured into ice-water, and extracted with diethyl ether.
• the combined ether extract is washed with water and brine, dried over magnesium sulfate. After filtration, the filtrate concentrated, and the residue is distilled in vacuo to yield the product as colorless liquid.
• a nitrogen purged 1000-ml three-neck round bottom flask is fit with magnetic stirrer, condenser, and dropping funnel.
• Powered lithium aluminum hydride (0.14 ⁇ 0.18 mol) is added followed by anhydrous THF (140 ⁇ 180 ml), which can be replaced by commercial 1.0 M lithium aluminum hydride in THF.
• a solution of the ethyl 2-cyanocarboxylate compound (0.06 ⁇ 0.08 mol) in ether ( ⁇ 200 ml) is added dropwise to keep the mixture in gentle reflux.
• the mixture is heated to gentle reflux for 3 hours. After being cooled down, the flask is put in an ice-water bath.
• a 1000-mL round-bottom flask is charged with 3,5-dimethylisoxazole (9.7 g, 0.1 mol) and water (200 ml). To this solution is added 1.0 M aqueous potassium hydroxide (200 mL). Nickel-aluminum alloy (1:1, 32 g, 0.2 mol) is added in portions over 1 hour. After about another two hours, the reaction mixture is filtered over celite, and the solid washed with additional water. The filtrate is extracted with methylene chloride once. The aqueous solution is acidified with concentrated HCl, and concentrated to dryness.
• a 250-ml round bottom flask is charged with aminoalcohol (0.02 mol), pyridine (0.04 mol, 1.0 equiv.) and methylene chloride (50 ml).
• the flask is immersed in an ice-water bath, and benzoyl chloride (0.04 mol, 1.0 equiv.) is added dropwise.
• the flask is warmed up to room temperature, and the mixture is stirred overnight.
• the mixture is diluted with methylene chloride, and washed with water, saturated ammonium chloride, water, saturated sodium bicarbonate, and brine, consequently.
• the solution is dried over magnesium sulfate, filtered, and the filtrate concentrated.
• the residue is purified by flash column chromatography to yield the product as a colorless oil or white solid.
• a 250-ml round bottom flask is charged with 3.75 g of 2-(aminomethyl)-2-isobutyl-4-methylpentan-1-ol, 3.24 mL of pyridine and 40 ml methylene chloride.
• the flask is cooled in ice-water bath and 8.67 g of biphenyl-4-carbonyl chloride is added in one portion. The reaction is warmed to room temperature and stirred overnight.
• reaction is diluted with 100 ml methylene chloride and washed subsequently with water, 1 N HCl (20 ml), water, saturated NaHCO 3 , and brine once (20 ml), the organic layer is dried over MgSO 4 , filtered off the solid, and concentrated and purified by column chromatography on silica gel to give desired compound as white powder.
• a procatalyst precursor (according to the weight shown in Table 2) and 2.52 mmol of internal electron donor (i.e., substituted amide ester) are charged into a flask equipped with mechanical stirring and with bottom filtration.
• 60 ml of a mixed solvent of TiCl 4 and chlorobenzene (1/1 by volume) is introduced into the flask.
• the mixture is heated to 115° C. and remains at the same temperature for 60 minutes with stirring at 250 rpm before filtering off the liquid.
• 60 ml of mixed solvent is added again and the reaction is allowed to continue at the same desired temperature for 30 minutes with stirring followed by filtration. This process is repeated once.
• 70 ml of iso-octane is used to wash the resultant solid at ambient temperature. After the solvent is removed by filtration, the solid is dried by N 2 flow or under vacuum.
• MagTi-1 is a mixed Mag/Ti precursor with a composition of Mg 3 Ti(OEt) 8 Cl 2 (a MagTi precursor prepared according to example 1 in U.S. Pat. No. 6,825,146) with an average particle size of 50 micron.
• SHACTM 310 is a benzoate-containing catalyst (a BenMag procatalyst precursor with an average particle size of 27 micron) with ethyl benzoate as the internal electron donor made according to Example 2 in U.S. Pat. No. 6,825,146, the entire content of which is incorporated herein by reference. Titanium content for each of the resultant procatalyst compositions is listed in Table 3. The peaks for internal donors are assigned according to retention time from GC analysis. No additional characterization is performed.
• Polymerization is performed in liquid propylene in a 1-gallon autoclave. After conditioning, the reactors are charged with 1375 g of propylene and a targeted amount of hydrogen and brought to 62° C. 0.25 mmol of DCPDMS is added to 7.2 ml of a 0.27 M triethylaluminum solution in isooctane, followed by addition of a 5.0 wt % procatalyst slurry in mineral oil (actual solid weight is indicated in data tables below). The mixture is premixed at ambient temperature for 20 minutes before being injected into the reactor to initiate the polymerization. The premixed catalyst components are flushed into the reactor with isooctane using a high pressure catalyst injection pump. After the exotherm, the temperature is controlled to 67° C. Total polymerization time is 1 hour.
• Polymer samples are tested for settled bulk density, melt flow rate (MFR), xylene solubles (XS), polydispersity index (PDI), and final melting point (T MF ). Unless specified, XS are measured using Viscotek method.
• Simple amide ester compounds such as compound 1 with two methyl groups at the central carbon atom (2-position) of C 3 spacer between the amide functional group and the ester functional group, show poor catalyst activity and poor catalyst selectivity (polymer isotacticity) as well as low final melting point (T MF ).
• T MF final melting point
• 1,3-positions are both substituted with methyl groups (compound 2)
• PDI values that are still significantly higher than what can be accomplished by a DiBP-based catalyst.
• Applicants also surprisingly discovered that improvement in catalyst activity and/or isotacticity can also be achieved by increasing the bulkiness of the substituents at the central carbon atoms. Examples include isopropyl (compound 3), and isobutyl (compound 4) replacing the methyl groups at 2-position (Table 4).

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